Case Study
Engineering Systems That Scale
Transforming a Rapidly Growing Manufacturer into a Streamlined, Data-Driven Operation
The Challenge: Growth Outpaced the Systems
A leading electronics manufacturer had grown from 400 to more than 1,000 employees in just a few years. With that growth came mounting inefficiencies:
Engineering change requests that bypassed vetting and created multiple product versions in inventory
Mismatched data between PLM and ERP systems
Rising compliance and testing costs
Inconsistent documentation and onboarding
Products requiring seven PCB design turns — more than double the industry norm
Teams were constantly firefighting. Leadership knew they needed structured systems to restore efficiency, reduce waste, and support scalable growth.
Our Process: Designing Efficiency from the Ground Up
Efficiency Edge partnered with the company to rebuild their engineering and production systems using structured improvement methodologies like DMAIC, Kaizen, and data-driven design analysis.
1. Redefining the Engineering Change Process
We began with a Kaizen event to map the entire engineering change workflow — from concept to release. The process revealed data mismatches, uncontrolled revisions, and unclear ownership.
Designed new workflows with standardized approvals and documentation
Created SOPs and a centralized tracking system
Aligned PLM and ERP integrations
Result: Reduced PCB design iterations from 7 to 3, saving $1M per year in time and materials, and another $2M per year by eliminating errors and rework.
2. Investing in Smarter Testing Systems
Testing inefficiencies were driving major costs across the organization. Efficiency Edge presented a data-backed business case that led leadership to invest in:
$3M in new PCB testing automation — which eliminated the need for physical test fixtures, reduced testing time by 25%, and removed costly fixture storage.
$1M in a new acoustics lab — improving accuracy for product testing and saving $250K annually by cutting external lab expenses.
These changes not only saved money but also gave engineering teams real-time insights for product improvement and faster market release cycles.
3. Controlling Compliance Costs
Annual compliance costs had grown unsustainably. By building an in-house safety lab, the company could test and certify products internally.
Result: A $160K investment saved $300K per year, breaking even within seven months.
4. Bringing Clarity to Documentation and Onboarding
Engineering documentation was fragmented across Teams folders and uncontrolled copies. Using the Design phase of DMAIC, we partnered with stakeholders to rebuild the entire document control system.
Established clear file structures, versioning, and access control
Implemented review and approval procedures
Result: Onboarding time dropped significantly, and engineers gained confidence that they were always using the correct version.
5. Eliminating Manufacturing Failures
A quarter of PCBs pulled from inventory failed due to “software” issues. Process mapping revealed no verification step in programming and testing.
We implemented a digital watermark system to verify that boards were correctly programmed before assembly.
Result: Software-related failures were completely eliminated.
6. Resolving Production Disputes with Data
A new product was failing 50% of the time in assembly, and engineering blamed manufacturing. We conducted a Gage R&R–style experiment to test variation across assemblers.
The results proved the failures stemmed from design, not assembly. Once corrected, first-pass yield improved to 99%.
7. Simplifying Performance and Accountability
To eliminate bottlenecks in performance reviews and create clarity across a team of 23 engineers and technicians, Efficiency Edge helped the organization:
Build a clear role ladder tied to company values
Define yes/no behavioral expectations
Standardize the review process company-wide
Result: Managers conducted faster, more consistent reviews — freeing leadership to focus on strategic improvement instead of firefighting.
The Results: Efficiency Engineered Into Every Layer
In under two years, the company went from reactive to reliable — with measurable gains across the board:
| Improvement Area | Result |
|---|---|
| Design Iterations | 7 → 3 (industry standard achieved) |
| Annual Engineering & Production Savings | $3.3M+ |
| Testing Efficiency | 25% faster and no test fixture storage |
| Compliance Cost Reduction | $300K saved annually |
| Product Testing Accuracy | Improved, saving $250K per year |
| Software-Related Failures | 100% eliminated |
| First-Pass Yield | 99% on new product lines |
| Onboarding Time | Reduced across engineering teams |
The Impact: Sustainable Systems for Scalable Growth
Efficiency Edge helped this growing manufacturer shift from chaos to control.
Engineering and manufacturing now operate under standardized, data-driven processes.
Testing and compliance are faster, cheaper, and more accurate.
Teams are aligned, onboarding is faster, and accountability is built into the system.
The result is a company that can scale confidently — with systems designed to deliver consistent quality and continuous improvement.
Ready to Eliminate Waste and Build Scalable Systems?
Efficiency Edge helps manufacturers and distributors turn operational complexity into clarity — using Lean principles, data-driven process design, and scalable systems that deliver measurable results.